Systems and methods for monitoring door opening events

ABSTRACT

A method to automatically audit the number of units within an enclosure having at least one door includes receiving from a remote telemetry device data indicating the number of times within a predetermined period of time a door has been opened to a predetermined open position relative to the enclosure, the predetermined open position of the door being specifically calibrated by a sensor device being mechanically set when the sensor device is installed on the enclosure proximal to the door as a position of the door between a closed position and a more fully opened position beyond the predetermined open position, to generate a door opening count, wherein the remote telemetry device includes a sensor configured to be adjustably calibrated to sense when the door is at the predetermined open position relative to the enclosure based upon the adjustable calibration, to generate the door opening count. A remote telemetry device for automatically auditing the number of items within an enclosure having at least one door for removal and restocking of the items that includes a remote telemetry device in communication with at least one sensor device configured to be calibrated, the calibration of the sensor device being set when the sensor device is installed based upon the size of an item, the sensor configured to detect the door opening to a calibrated door open position, data indicative of the number of items within the enclosure to determine a current count.

RELATED APPLICATION

This application is a divisional of U.S. patent application Ser. No.16/395,580 filed Apr. 26, 2019, which claims priority to and the benefitof Australia Patent Application No. 2018202899 filed Apr. 27, 2018,which are incorporated by reference herein in their entirety.

TECHNICAL FIELD

The present disclosure relates to systems and methods for monitoringdoor opening events, and more particularly, to calibrating door openingsensors for specific door opening events. The present disclosure furtherrelates to making predictions of the number of units within an enclosurebased upon data gathered by one or more sensors.

BACKGROUND

Enclosures are built for many different purposes. Paddocks, pens, yardsand cages are examples of enclosures. Buildings, boxes and bags of anykind are also enclosures. Enclosures are used to keep items, animateand/or inanimate therein, or to keep items out of the enclosure. Anymaterial out of which an enclosure is made, or its purpose is withinthis definition of enclosures. Typically access to an enclosure of aspace is through an opening of the enclosure that can be secured by, forexample in the case of buildings, paddocks etc., a door or a gate.

Enclosures are designed and built for storing specific types ofproducts. For example, retail outlets and petrol stations commonly housegas cylinders in a locked outdoor storage cage. Customers are typicallygiven a key to open the storage cage on their own to access and swap anempty cylinder for a full cylinder. The inventory in the cage is usuallyowned and managed by a separate gas cylinder supply business, and theoperator of the retail outlet is generally not responsible formonitoring or advising the gas cylinder supply business of the inventorylevel, which presents a problem of inventory and distributionmanagement.

Another example of an enclosure built for storing a specific type ofproduct is an ice freezer that is typically outside of a retail outlet.Typically, retail outlets are arranged so that a customer pays for theice at an indoor cash register. The customer then goes outside theretail outlet and removes the number of bags of ice that they justpurchased. Not only is inventory management a problem, but potentiallytheft is a problem as well.

SUMMARY

According to a first aspect, the present disclosure provides anelectro-mechanical adjustable monitoring system configured to monitordoor opening events of an enclosure's door connection system, the systembeing configured to allow a door to open to a predetermined openposition relative to the enclosure wherein the door is capable of beingopened to a more fully opened position beyond the predetermined openposition, the monitoring system comprising: at least one sensor deviceconfigured to be adjustably calibrated when the sensor device isinstalled on the enclosure proximal to the door to sense when the dooris at the predetermined open position relative to the enclosure thepredetermined open position adjustably specifically calibrated by thesensor as a position of the door between a closed position and the morefully opened position beyond the predetermined open position, so thatthe sensor device is configured to detect when the door has been openedto at least the predetermined open position relative to the enclosurebased upon the adjustable calibration mechanically set when the deviceis installed proximal to the door, the sensor device providing sensoroutput.

According to a second aspect, the present disclosure provides a methodautomatically auditing the number of units within an enclosure having atleast one door, comprising: receiving from a remote telemetry devicedata indicating the number of times within a predetermined period oftime a door has been opened to a predetermined open position relative tothe enclosure, the predetermined open position of the door beingspecifically calibrated by a sensor device being mechanically set whenthe sensor device is installed on the enclosure proximal to the door asa position of the door between a closed position and a more fully openedposition beyond the predetermined open position, to generate a dooropening count, wherein the remote telemetry device includes a sensorconfigured to be adjustably calibrated to sense when the door is at thepredetermined open position relative to the enclosure based upon theadjustable calibration, to generate the door opening count.

According to a third aspect, the present disclosure provides a remotetelemetry device for automatically auditing the number of items withinan enclosure having at least one door for removal and restocking of theitems, comprising: a remote telemetry device in communication with atleast one sensor device configured to be calibrated, the calibration ofthe sensor device being set when the sensor device is installed basedupon the size of an item, the sensor configured to detect the dooropening to a calibrated door open position, data indicative of thenumber of items within the enclosure to determine a current count.

According to a further aspect, the present disclosure provides anelectro-mechanical adjustable monitoring system configured to monitordoor opening events of an enclosure's door connection system, the systembeing configured to allow a door to open to a predetermined openposition relative to the enclosure wherein the door is capable of beingopened to a more fully opened position beyond the predetermined openposition, the monitoring system comprising: at least one sensor deviceconfigured to be adjustably calibrated when the sensor device isinstalled on the enclosure proximal to the door to sense when the dooris at the predetermined open position relative to the enclosure thepredetermined open position adjustably specifically calibrated by thesensor as a position of the door between a closed position and the morefully opened position beyond the predetermined open position, so thatthe sensor device is configured to detect when the door has been openedto at least the predetermined open position relative to the enclosurebased upon the adjustable calibration mechanically set when the deviceis installed proximal to the door, the sensor device providing sensoroutput.

According to a further aspect, the present disclosure provides a methodof an adjustable electro-mechanical monitoring system configured tomonitor an enclosure's door opening events, comprising: providing asensor device for an enclosure having a door capable of opening to apredetermined open position relative to the enclosure wherein the dooris capable of being opened to a more fully opened position beyond thepredetermined open position and capable of being in a closed position,wherein the sensor device is adjustably mechanically calibrated when thedevice is installed on the enclosure proximal to the door to sense whenthe door is at the predetermined open position relative to the enclosuresuch that the sensor is adjustably specifically calibrated to sense whenthe door is at the predetermined open position and wherein when thesensor device detects when the door has been opened to at least thepredetermined open position relative to the enclosure based upon theadjustable calibration, the sensor device is capable of providing sensoroutput.

According to a further aspect, the present disclosure provides a sensordevice for sensing when a door of an enclosure is opened to apredetermined open position relative to the enclosure wherein the dooris capable of being in a closed position and being opened to a morefully opened position beyond the predetermined open position, the sensordevice configured to be calibrated comprising an arm wherein when thedoor opens, the arm slides against the door resulting in a switch eventwhen the door is opened to the predetermined open position relative tothe enclosure, the switch event resulting in sensor output, wherein theposition of the arm relative to the enclosure is specifically adjustablycalibrated to sense by sliding against the door when the door is at thepredetermined open position relative to the enclosure, based upon theadjustable calibration.

According to a further aspect, the present disclosure provides a methodautomatically auditing the number of units within an enclosure having atleast one door, comprising: receiving from a remote telemetry devicedata indicating the number of times within a predetermined period oftime a door has been opened to a predetermined open position relative tothe enclosure, the predetermined open position of the door beingspecifically calibrated by a sensor device being mechanically set whenthe sensor device is installed on the enclosure proximal to the door asa position of the door between a closed position and a more fully openedposition beyond the predetermined open position, to generate a dooropening count, wherein the remote telemetry device includes a sensorconfigured to be adjustably calibrated to sense when the door is at thepredetermined open position relative to the enclosure based upon theadjustable calibration, to generate the door opening count.

According to a further aspect, the present disclosure provides a methodfor automatically auditing the number of items within an enclosurehaving at least one door for removal and restocking of the items,comprising: receiving from a remote telemetry device in communicationwith at least one sensor device configured to be calibrated, thecalibration of the sensor device being set when the sensor device isinstalled based upon the size of an item, the sensor configured todetect the door opening to a calibrated door open position, dataindicative of the number of items within the enclosure to determine acurrent count.

According to a further aspect, the present disclosure provides a methodfor automatically auditing the number of gas cylinders within anenclosure having at least one door for removal and restocking of the gascylinders, comprising: receiving from a remote telemetry device incommunication with at least one sensor configured to be calibrated basedupon the size of a gas cylinder, the sensor configured to detect thedoor opening to a calibrated door open position, data indicative of thenumber of gas cylinders within the enclosure to determine a currentcount; and applying a characteristic correlation factor to the currentcount to generate a prediction of when units in the enclosure will reacha predetermined inventory.

According to a further aspect, the present disclosure provides a methodfor automatically auditing the number of items within an enclosurehaving at least one door for removal and restocking of items,comprising: receiving from a remote telemetry device in communicationwith at least one sensor configured to be calibrated based upon the sizeof an item to detect a door opening enough so that the item can passthrough the door, the sensor configured to detect the door opening to acalibrated door open position, data indicative of the number of gascylinders within the enclosure to determine a current count; andapplying an historical correlation factor to correct the current countto generate a prediction of when units in the enclosure will reach apredetermined inventory.

According to a further aspect, the present disclosure provides a methodfor automatically auditing the number of items within an enclosurehaving at least one door for removal and restocking of items,comprising: receiving from a remote telemetry device in communicationwith at least one sensor configured to be calibrated based upon the sizeof an item to detect a door opening enough so that the item can passthrough the door, the sensor configured to detect the door opening to acalibrated door open position, data indicative of the number of gascylinders within the enclosure to determine a current count; andapplying a characteristic correlation factor to the current count togenerate a prediction of when units in the enclosure will reach apredetermined inventory.

Disclosed is a monitoring system for monitoring an enclosure's dooropening events. A door of any type is connected to an enclosure whereina door connection system, such as door hinges, is configured to allow adoor to open and close. Disclosed is at least one sensor which isconfigured to detect when the door has been opened to a specificallycalibrated position sufficient to allow the removal of the enclosedproduct between closed and fully open positions relative to theenclosure, the sensor providing sensor output. Also disclosed is ananalyzing system configured to analyze the sensor output

As mentioned, regarding enclosures, the present disclosure refers toself-service retail inventory management. The discussion below is withrespect to a system and method for retrofitting an existing storagecage, particularly of the type that is used for the retail market forpropane (LPG) cylinders (for example 9 kg) used in domestic barbeques.In another use case, for example, Forklift LPG cylinder cages areimportant in business-to-business operations where a warehouse/factoryhas multiple forklifts which need regular LPG cylinder swaps to fuelforklifts. In this instance, theft is not the concern, rather it isprimarily continuity of supply that is important. However, any type ofsituation, enclosure and door are contemplated in the presentdescription.

As mentioned, in the retail market for 9 kg propane (LPG) cylinders,retail outlets commonly house the gas cylinders in an outdoor storagecage with a locked door. Since the operator of the retail outletgenerally is not responsible for monitoring or advising the gas cylindersupply business of the inventory level, the gas cylinder supply businesswould benefit from a retro-fit system providing an improved inventorymonitoring capability. Readily available door counters that sense when adoor is in an opened position and when it is in a closed position arenot configured to detect when the door has been opened to a positionspecifically calibrated between the closed and fully opened positions tomore reliably track when a specifically dimensioned product has beenremoved.

In situations as described above, it would be beneficial if sensor dataprovided output correlated to a specific calibrated opening position ofa door. For example, particularly for enclosures that are outdoors, adoor may have tendency to move due to wind or contact, therefore,commercially available door counters may provide false counts ofrelevant door openings. Enclosures may be built to low dimensionaltolerances, allowing some free movement of doors even when secured inthe “closed” position. Also, enclosures may be subject to various formsof in-service abuse, leading to doors which are bent or twisted.

Disclosed is a monitoring system and method for monitoring door openingevents of an enclosure's door connection system being configured toallow the door to open to a predetermined open position relative to theenclosure wherein the door is capable of being opened beyond thepredetermined open position, the monitoring system including at leastone sensor device configured to be calibrated to sense when the door isat the predetermined open position relative to the enclosure so that thesensor device is configured to detect when the door has been opened toat least the predetermined open position relative to the enclosure, thesensor device providing sensor output.

Therefore, it is an object of the presently disclosed system formonitoring an enclosure's door opening events to at least ameliorate theabove-described problems and to further provide a sensor deviceconfigured to be specifically calibrated to individual door openingevents. In one embodiment, the calibration process can occur during aretro-fit installation process of the sensor device proximal to theenclosure. In another embodiment, the calibration process may occur in afactory installation process or be prefabricated to a specificcalibration.

Disclosed is one or more monitoring systems and methods for monitoringan enclosure's door opening events. Disclosed is a sensor device isconfigured to be specifically calibrated to sense when the door is atthe predetermined open position relative to the enclosure, the sensordevice providing sensor output and a telemetry output system configuredto transmit the sensor output.

Also disclosed is a sensor device that may include an arm wherein whenthe door opens, the arm slides against the door resulting a switch eventwhen the door is opened to the predetermined open position relative tothe enclosure, the switch event resulting in sensor output.

Also disclosed is a telemetry output system configured to transmit thesensor output. Additionally, disclosed is a monitoring system whereinthe sensor output provides at least one of a count of when the door hasbeen opened to at least the predetermined open position relative to theenclosure and a time stamp of when the door has been opened to at leastthe predetermined open position relative to the enclosure. Alsodisclosed is a monitoring system wherein the sensor output is providedat predetermined time intervals. Moreover, disclosed is a monitoringsystem wherein the sensor device comprises an arm such that when thedoor opens, the arm slides against the door resulting in a switch eventwhen the door is opened to the predetermined open position relative tothe enclosure, the switch event resulting in sensor output. Alsodisclosed is a monitoring system wherein the sensor device is configuredto be calibrated during installation proximal to the enclosure by fixingthe arm position relative to the enclosure. Furthermore, disclosed is amonitoring system of claim 1, wherein the sensor device provides imagesensor output. Also disclosed is a monitoring system wherein the sensordevice is configured to be calibrated during installation proximal tothe enclosure. As well is disclosed a monitoring system wherein thesensor device comprises an arm and at least one housing member whereinduring installation, the arm and the housing member are loosely boundprior to calibration, and then tightly bound upon calibration.

Disclosed is a method for automatically auditing the number of unitswithin an enclosure having at least one door including receiving from aremote telemetry device data indicating the number of times within apredetermined period of time a door has been opened to a predeterminedopen position relative to the enclosure wherein the door is capable ofbeing opened beyond the predetermined open position to generate a dooropening count, wherein the remote telemetry device includes a sensorconfigured be calibrated to sense when the door is at the predeterminedopen position relative to the enclosure. Also disclosed is a method ofreceiving the number of units positioned within the enclosure at a priorparticular time and determining from the data indicating the number oftimes within a predetermined period of time a door has been opened to apredetermined open position relative to the enclosure and the number ofunits positioned within the enclosure at a prior particular time, acurrent count. Additionally, disclosed is a method of claim of applyingan historical correlation factor to the current count to generate aprediction of when units in the enclosure will reach a predeterminedinventory. Furthermore, disclosed is a method of applying acharacteristic correlation factor to the current count to generate aprediction of when units in the enclosure will reach a predeterminedinventory number.

Disclosed is a method for automatically auditing the number of gascylinders within an enclosure having at least one door for removal andrestocking of the gas cylinders including receiving from a remotetelemetry device in communication with at least one suitable sensor,data indicative of the number of gas cylinders within the enclosure todetermine a current count and applying an historical correlation factorto correct the current count to generate a prediction of when units inthe enclosure will reach a predetermined inventory. Also disclosed is amethod of applying a characteristic correlation factor to the currentcount to generate a prediction of when gas cylinders in the enclosurewill reach a predetermined inventory number.

Disclosed is a method for automatically auditing the number of gascylinders within an enclosure having at least one door for removal andrestocking of the gas cylinders, including receiving from a remotetelemetry device in communication with at least one suitable sensor,data indicative of the number of gas cylinders within the enclosure todetermine a current count and applying a characteristic correlationfactor to the current count to generate a prediction of when units inthe enclosure will reach a predetermined inventory. Also disclosed is amethod of applying an historical correlation factor to the current countto generate a prediction of when gas cylinders in the enclosure willreach a predetermined inventory number.

The instant disclosure is provided to explain in an enabling fashion thebest modes of making and using various embodiments. The disclosure isfurther offered to enhance an understanding and appreciation for theembodiments principles and advantages thereof, rather than to limit inany manner the scope of the claims. While the embodiments areillustrated and described here, it is clear that the scope of the claimsis not so limited. Numerous modifications, changes, variations,substitutions, and equivalents will occur to those skilled in the arthaving the benefit of this disclosure without departing from the spiritand scope of the following claims.

It is understood that the use of relational terms, if any, such as firstand second, up and down, and the like are used solely to distinguish onefrom another entity or action without necessarily requiring or implyingany actual such relationship or order between such entities or actions.

Much of the inventive functionality and many of the inventive principlesare best implemented with or in software programs or instructions andintegrated circuits (ICs) such as application specific ICs. In theinterest of brevity and minimization of any risk of obscuring theprinciples and concepts according to the present embodiments, discussionof such software and ICs, if any, is limited to the essentials withrespect to the principles and concepts within the embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a gas cylinder cage including a hinged door connected toan enclosure;

FIG. 2 depicts an item, in this case, a gas cylinder which is positionedbetween the door and the enclosure for example, for the purpose ofcalibration;

FIG. 3 shows a top down view of cylinder 16 in a position between thedoor 12 and the enclosure 14 of FIG. 2 ;

FIG. 4 depicts an installed bracket;

FIG. 5 depicts an expanded view of an embodiment of the disclosed sensordevice;

FIG. 6 depicts a sensor device prior to calibration;

FIG. 7 depicts a sensor device after calibration;

FIG. 8 depicts a switch of a sensor device that may provide sensoroutput of an embodiment of a sensor device;

FIG. 9 depicts a system incorporating a sensor device into adistribution system;

FIG. 10 depicts a flow chart illustrating one or more disclosed methodsof predicting the count of gas cylinders in an enclosure;

FIG. 11 is a graph illustrating hours on the x-axis and the number ofunits on the y-axis; and

FIG. 12 is a graph depicting a prediction made with the application offand/or f c.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Disclosed is a monitoring system for monitoring an enclosure'sspecifically calibrated door opening events. As mentioned above, whilethis description uses a gas cylinder cage as an example enclosure 14,there is no intention to limit enclosures of this disclosure to only gascylinder cages. In FIG. 1 , the door 12 of the gas cylinder cage 10 isshown as a hinged door. While this description uses a gas cylinder cagehinged door as an example door, there is no intention to limit doors ofthis disclosure to hinged doors. For example, roller doors, slidingdoors, folding doors, as well as any other door type having a variableopening capability can be configured with a disclosed sensor devicewhich provides the ability to sense the door opening to a specificallycalibrated predetermined open position relative to the enclosure. Shownin FIG. 1 is an angle iron front panel configuration for supportinghinges but any enclosure/door configuration is within the scope of thisdiscussion.

FIG. 2 depicts an item, in this case, a gas cylinder 16 which ispositioned between the door 12 and the enclosure 14, for example, forthe purpose of calibration. Shown, is the door 12 having been moved in adirection 18 so that it would otherwise be in a closed position were itnot for the gas cylinder 16 in between the door 12 and the enclosure 14.In a situation such as where there is unsupervised access to thecontents of an enclosure, sensing and reporting if and/or when the doorhas been opened enough to allow a cylinder 16 to be removed from theenclosure 14 may provide relevant sensor data. Depending upon theenclosure and the items stored therein, in this example, gas cylinders,or in another example, a bag of ice, specific calibration uponinstallation may allow the disclosed sensor device to sense when thedoor has been opened just enough to allow an item stored therein to beremoved.

A top down view of cylinder 16 in a position between the door 12 and theenclosure 14 of FIG. 2 is shown FIG. 3 . In this embodiment, the door istherefore in a desirable position for sensing when the door 12 is at thepredetermined open position relative to the enclosure 14. Moreparticularly, a gas cylinder 16 would not be able to be moved out of theenclosure 14 if the door 12 were not opened to at least the shownpredetermined open position relative to the enclosure 14. The door 12 isstill capable of being opened beyond the predetermined open position,but at a minimum, the door 12 is opened such that a gas cylinder 16 maybe removed or added to the gas cylinder cage 10. Most likely, the sizeof an item would be used by a user of the disclosed systems and methodsfor calibrating the predetermined open position of the door 12, but notnecessarily. Any calibration at any predetermined open position of thedoor 12 is within the scope of this discussion.

FIG. 3 further depicts in an inset 18, an embodiment of the disclosedsystems and methods. In this embodiment, a sensor device 20 is placednear where the door 12 meets the enclosure 14. In this embodiment, anarm 22, for example spring-loaded, of the sensor device 20 slidesagainst or along the door 12 resulting in a switch event when the door12 is opened to the predetermined open position relative to theenclosure 14, the switch event resulting in sensor output. In thisillustrated embodiment, the switch is mechanical, not requiring power.In this embodiment, a processor 24, for example, may be incorporatedinto a telemetry output system 26. It is understood that some or all ofthe features described herein or otherwise may be incorporated into oneor more housings. For example, all of the features or elements describedherein may be housed in a single housing. Other alternatives, such asthe telemetry output system 26 may be housed in a housing separate fromthe sensor device 20. The sensor output may be received by the processor24 and transmitted by the telemetry output system 26 configured totransmit the sensor output. Power required for the processor 24 and thetransmitter or transceiver of the telemetry output system 26 may beprovided by a battery (not shown). A battery plus a capacitive elementfor storing power for data bursts may be incorporated into the telemetrydevice. One or the other, or a combination of transmission schedulingand compression of data by the telemetry device may conserve power ofthe telemetry output system 26. The sensor data from the cage sensordevice 20 and transmitting the data via the telemetry output system 26to a remote location maybe used, for example, by an inventory managementand distribution system.

In one embodiment, the telemetry output system 26 may transmit data viaa cellular mobile network or an Internet of Things (IoT) network.However, many other telemetry techniques can be used to transmit andreceive data, for example, fixed telephone or internet line (copper,fiber), LP-WAN (public and/or private), private radio link e.g. ISMband, Wi-Fi or satellite communications. Optionally, a disclosed sensordevice 20 can be arranged to transmit to a nearby transceiver which iscapable of transmitting to a network. For example, the transmissionbetween sensor device 20 and a transmitter can be through a cable orprivate radio link, and the transmission to the network can be via acellular network, LP-WAN or fixed telephone or internet line. If two-waytransmission is enabled, data may be received for example, to updatesoftware/firmware of the processor 24. The sensor output may bemanipulated or compressed by the processor 24 for efficient use ofenergy in transmission.

In another embodiment, the use of a switch 46 (or other means forreceiving or providing sensor output) as described below together with alocally mounted totalizer may provide sensor output that could be readby a person for subsequent data entry and processing. A manualinspection of a counter device may provide information to an observer ofa count, for example, of the number of times that the door is opened tothe specifically calibrated opened position.

FIG. 4 depicts a disclosed system which can be retrofitted to existinggas bottle cages or any type of enclosure with a door by attaching thedisclosed sensor device system to an attached bracket. A bracket 28 maybe removably attached to the enclosure 14 with for example a screw and ascrew driver 30, or with a hammer and nail, or not attached butpositioned. It is understood that any manner in which to install anembodiment of the disclosed systems and methods to an enclosure of anytype is within the scope of this discussion.

FIG. 5 depicts an expanded view of an embodiment of the disclosed sensordevice. The disclosed sensor device 20 may be packaged in disassembledparts as shown in FIG. 5 . A processor, transmitter and battery as shownin FIG. 3 may come with one or more sensor devices 20 since an enclosuremay include more than one door.

In one embodiment, at least one housing member, or more than one housingmembers, for example, a top cover 34 and a bottom housing 36 may bealigned with the arm 22 by a user so that a fastening device such as ascrew 38 may loosely bind them together. In one embodiment, thetightening of the screw 38 may be incomplete, leaving a gap 40 shown inFIG. 6 . At this point, the pictured sensor device 20 may be heldtogether, but it is not in a completely assembled state. The picturedsensor device 20 may then be attached to a bracket 28, such as thatshown in FIG. 4 . Depending upon how the door 12 is opened, to theright, or to the left, either one of flanges 42 or 44 may be used tohold the sensor device 20 in place on a bracket 28. Also, depending uponthe orientation of the device, the different parts may be aligned in adifferent order than that shown.

At the point of installation depicted in FIG. 3 , an item 16 may beplaced between the door 12 and the enclosure 14. The arm 22 cantherefore be moved so that it aligns with the position of the door 12.The arm is thus configured to be at the specifically calibratedpredetermined open position relative to the enclosure. The door may alsobe opened farther than the predetermined open position. Accordingly, thedoor then may be opened farther allowing a user access to screw 38 so itmay be tightened so that the gap 40 shown in the sensor device of FIG. 6is closed as shown in FIG. 7 .

FIG. 8 depicts an embodiment for a switch mechanism of the sensor device20 for providing sensor output. As described above, any type of sensormay be utilized as a sensor device 20, and therefore the manner in whichto capture switch events may be dependent upon the type of sensorutilized. In the illustrated embodiment, an arm 22 of a sensor device 20may move along a door 12 as it opens so that the arm 22 slides againstthe door 12 as described above. Once the door reaches the predeterminedopen position set by the calibration process described above, a switch46 event may occur when the door 12 is opened to the predetermined openposition relative to the enclosure 14. The switch event results insensor output provided to the processor 24 and/or the telemetry outputsystem 26.

Still referring to FIG. 8 , a switch event may be triggered when an axle36 including a tab 48 moves in direction 50 when the arm 22 moves whilethe door 12 is opening. During the calibration process, the axle 36 hadbeen adjusted so when the tab 48 reaches the switch 46, the door 12 andtherefore the arm 22 are at the predetermined open position relative tothe enclosure 14, resulting in a switch event. A tactile/physicalfeedback when the door is opened to predetermined open position may beprovided or not provided.

Validating a door opening event as significant so that interpretation ofthe door opening event data is accurate is within the scope of thisdiscussion. For example, factoring a margin of error may improveaccuracy. Other validating features may include collecting dataindicative of the time spent that the door stays open at or past thepredetermined open position. For example, a switch event may occur whenthe door is closed and passes the specifically calibrated door openingposition. Alternatively, a different switch may monitor door closingevents at a different point than the specifically calibrated dooropening position. In this manner, the time spent while the door is openat or beyond the specifically calibrated open position may be captured.The time that the door is open may be indicative of the number of itemsremoved or added to the enclosure. For example, if the time spent openat the specifically calibrated open position is between 10-20 seconds,that may indicate that one item was being removed during that time. Ifthe time that the door is open is 3 minutes, that may indicate that theenclosure has been restocked. Such data may be transmitted from thetelemetry output system 26 and received remotely for example, at aremote server, for example, not waiting for a regular periodic reportingtime but substantially immediately when there is a substantial deviationfrom the normal time that is spent with the door open at or beyond thespecifically calibrated. When there is a substantial deviation from thetime normally spent with the door open at or beyond the specificallycalibrated, that time may be compared with a distributor's records whichmay be stored, for example, at remote server, to determine if in factthe data correlates with a delivery. If the data is substantiallyoutside predicted data (which is described below), there may be anindication, for example, that the door was left open accidentally, orthat there has been a theft

It is understood that the embodiment of the sensor device 20 describedabove is one manner in which to carry out the disclosed systems andmethods. Another method may include utilizing image capture andcalibrating the image capture system to generate suitable sensor outputwhen the door 12 is at the predetermined open position relative to theenclosure 14 (see FIGS. 2 and 3 ). For example, with a camera of anysuitable type positioned appropriately can capture removal from orstocking of gas cylinders into a gas cage enclosure. To extend acamera's battery life, for example, a motion sensor can sense motionnear a gas cylinder cage. The motion sensor may initiate the camera towake up so that it can capture removal or stocking of gas cylinders. Ina similar fashion to the described partial door opening sensor, acalibration image may be stored. That is, while the camera is in itsposition to capture removal or stocking of gas cylinders, a calibrationimage may be specifically captured of a gas cylinder being removed orbeing stocked in the gas cylinder cage. That calibration image may be,for example, stored locally or remotely. The camera may be incommunication with a local or remote processor that can compare acaptured image with the calibration image to filter the camera captureddata to better assure that data output delivered by the camera as toremoval or stocking of gas cylinders is more reliable than it would bewithout a comparison step.

Some other alternative methods of determining door opening which may becalibrated to sense opening at a predetermined door opening positioninclude, for example: a magnetic reed switch: place the magnet on anadjustable element (e.g. the arm) to allow set point variation; amagnetic reed switch: use a reed switch/magnet pair in place of thecurrent micro-switch and activation element in the axle moulding; acapacitive sensing device: capacitance varies with distance so a platethat moves as the door opens can be used; a capacitive sensing device:capacitance varies with element size so an appropriate encoder disc canbe used to calculate angular movement; an inductive sensing device:techniques like linear variable differential transformers, variableinductance measurement; a resistive sensing device: a potentiometercould be driven by the arm and the position determined; an opticalsensing device: any of numerous forms of encoder disc could be used toprovide either binary (open/closed) or rotational position detection.With the exception of the reed switch implementation, others describedmay require powering of the sensing element or device whether the switchis open or closed; i.e. the sensor dissipates power continually (orelse, to conserve power, the controlling device needs to duty-cycle thepower to the sensor i.e. monitor the door periodically, e.g. everyseconds). Any other manner in which to carry out the disclosed systemsand methods is within the scope of this discussion.

The present disclosure includes systems and methods for trackinginventory levels in an enclosure as a function of time. The systemincludes a sensor device for detecting each time the cage door is openedjust wide enough to pass a particular sized item through it, a telemetryoutput system 26 for receiving door opening data from the sensor device20 and transmitting it to a remote location, a re-stocking datacollection system for collecting re-stocking data about re-stockingevents at the enclosure, a computer processor for receiving the dooropening data and the re-stocking data and calculating historical iteminventory levels in the enclosure as a function of time.

Up until this point, this disclosure has mostly described a particularsensor capable of calibration to a partial door opening. It isunderstood that treatment of data output is independent of the manner inwhich the data was generated. That is, any suitable sensor or sensorsfor determining the number of cylinders in an enclosure is within thescope of this discussion as it relates to FIGS. 9-12 . Different methodswere discussed above, and any suitable method or system of determiningthe number of units in an enclosure is within the scope of thisdiscussion for making a prediction of the number of units in anenclosure at a later time.

FIG. 9 illustrates an embodiment of a distribution system incorporatingthe sensor unit 20 which may include the function of analysis of thesensor 20 output. The re-stocking data collection system may involveeach delivery driver 52 inputting data on, for example, their mobiledevices, about their item deliveries, such as, the date and time ofdelivery, the quantity of items delivered to the enclosure, the quantityof items removed from the enclosure, the number of times the enclosurewas opened (usually once only) as part of the re-stocking process. Thisdata may enable the processor, local or remote, to reconcile the dooropening data with the actual number of items delivered. Thereconciliation may be useful because each door opening does not alwayscorrelate with removal or stocking of an item. There may be multipleremovals of items per door opening, or there may be multiple dooropenings per removal of items.

The processor 24 and/or one or more other processors, for example, of aserver 60 receiving data from for example the Cloud 54 and/or a database56 and/or database 58, or any suitable combinations of networkconfigurations may also estimate the inventory in real time based on acalculated historical correlation between the number of door openings tothe specifically calibrated position and actual number of itemsdelivered. For example, the processor may calculate an historicalcorrelation of C=f_(D), where C is the actual number of items delivered,D is the number of partial door openings to the calibrated positionmeasured by a disclosed sensor device 20, and f is a historicalcorrelation factor for an enclosure. For example, if f=1.05, an averageof 1.05 items are actually removed for every door opening. When partialdoor opening to the calibrated position data is received by theprocessor, the processor may use the value off to estimate the number ofitems that have been removed up to that point in time from the priorinventory which may be calculated or empirically determined according toa recorded prior restocking event.

The processor may update the value off over time by using a rollingaverage of data for C and D, for example a rolling average over a periodof time (e.g. over the last 4 weeks) or over a fixed number of itemsdelivered (e.g. over the last 500 items delivered to an enclosure).

The processor may also maintain one or multiple f_(C) historical orpredictive characteristic correlation factor values reflecting variablesincluding, for example, the season of year and or annual event such as apublic holiday e.g. Thanksgiving, summer, day of the week, time of day,etc. The characteristic correlation factor may be pre-characterizedutilizing historical trends wherein one or more predetermined set ofcharacteristic values can be stored and accessed depending upon theseason, holiday events and the time of day for a particular geographicarea, and/or even as granular as for a particular enclosure onceanalyzed. Also, one or multiple fc values may be predictive.

The telemetry output system 26 may be arranged to report data inresponse to one or more triggers or switch events. An example of atrigger is the time elapsed since the last report was sent e.g. reportdata every one hour, six hours, 12 hours, or 24 hours. Another exampleof a trigger is the time of day e.g. report data at 6 am, 12 pm and 6pm. Another example of a trigger is when the number of door openingssince the last re-stocking event reaches a pre-set number. There can bemultiple pre-set numbers e.g. 15 and 20 items. The pre-set number can beset for each cage. For example, for a cage with a capacity of 21 items,the pre-set number may be 7, which means the telemetry output system 26may report data when the inventory is estimated to be 33% of capacity.This type of trigger has a number of advantages over a fixed reportingschedule. For example, it may reduce the number of times at which thetelemetry unit reports data, which saves battery power andtelecommunication costs. Also, it reports data in the event there are anunexpectedly large number of removals between scheduled reporting times.The telemetry output system 26 can include both multiple triggers. Forexample, it can report at scheduled times (e.g. 12 pm every day) pluswhenever the number of door openings to the specifically calibratedposition since the last re-stocking event reaches a pre-set number.

The disclosed systems and methods may collect data from a sensor device20 and use a dialer or telemetry output system 26 to transmit the datawirelessly via the cloud or otherwise to a database 56 of FIG. 9 . Thedata, for example, may include, account number, location code, enclosurenumber, sample date and time, opening count, last call date andmaintenance state.

Delivery units may also record and report data, for example, accountnumber, location code, enclosure number, enclosure capacity, deliverydate and time, number of items delivered and number of times the door 12was opened to the specifically calibrated door opening position or afully opened position for refreshing. The delivery unit's data may beentered into a different database than that of the sensor device 20, orthe same database. If entered into different databases, for exampledatabase 58, one or more servers 60 running delivery management softwareprocesses data from more than one database calculates historical iteminventory levels in the enclosure as a function of time, as well as alive estimate of the current item inventory.

There are several technical benefits of the disclosed sensor device.First, its operating power requirements are minimal, particularly in thecase of a mechanical switch. Another is the ease of retro-fitting anexisting enclosure with the device. Another benefit is that thedisclosed sensor device 20 has limited/minimal manufacturingrequirements. Also, the sensor device is versatile, wherein it is usefulfor a variety of enclosure door configurations. Other configurations mayalso provide technical benefits

As illustrated in FIG. 9 , a server 60 may receive data from, forexample, the Cloud 54 and/or a database 56 and/or database 58, or anysuitable combination of network configurations and may carry out amethod for automatically auditing the number of units within anenclosure having at least one door. The method can include the server 60being configured to receive from a remote telemetry device 20 dataindicating the number of times within a predetermined period of time adoor has been opened to a predetermined open position relative to theenclosure to generate a door opening count wherein the door is capableof being opened beyond the predetermined open position. The disclosedremote telemetry device can include a sensor configured be calibrated tosense when the door is at the predetermined open position relative tothe enclosure.

Receiving available unit data can include receiving data of priordistribution event and calculating the current number of units byutilizing the door opening events. Also contemplated is receiving from aremote telemetry device including at least one sensor, data indicativeof the number of gas cylinders within the enclosure to determine aresultant current count. Also contemplated is receiving from a remotetelemetry device including at least one sensor, data indicative of thenumber of units of any type of inventory. Above, different types ofsensing methods were discussed, wherein it is understood that any typeof sensor is included in this discussion.

Referring to FIG. 10 , a method of calculating a prediction of whenunits in an enclosure will reach a predetermined inventory number isdepicted. FIG. 11 refers to a prediction curve which could be generatedby one or more disclosed methods. In this way, a distributor ofinventory units can rely on a prediction for determining deliverytimetables and routes. The benefits may include at least that enclosuresmay not run out of inventory while there is still demand for theinventory and that the distributor may not waste resources by refillingthe enclosure before it is necessary to do so. Therefore, resources maynot be wasted by either users of the inventory making a trip to obtaininventory units when the stock has been depleted, or by the distributionsystem making a trip to the enclosure before there is a need to restockit.

FIG. 10 depicts a step 70 including that at least one sensor determinesthe number of times within a predetermined period of time a door hasbeen opened to a predetermined open position relative to the enclosure,for example, by counting or time stamping door opening events. Forexample, a time period of thirty minutes may be used as an interval forwhich a telemetry device in communication with at least one sensor ofthe enclosure to transmit data to a remote server, at step 72. To saveenergy, an option can include programming the telemetry device totransmit during hours in which there are transactions, as for example,during business hours. Other times, when the enclosure may not beaccessible, the processor may be programmed to avoid sending updates.

At the server, data may be received from the telemetry device indicatingdoor opening events. It may be determined that the data should beanalyzed at intervals of twenty-four hours at step 74. Any othersuitable time may be used to collate the data received from thetelemetry device 20 at step 76. In this manner, the method includes atstep 78 determining the number of units from door opening eventscompared to prior inventory or from any other means. For example, themethod for auditing the number of gas cylinders within an enclosure caninclude receiving from a remote telemetry device 20 which includes atleast one sensor of any suitable type, data indicative of the number ofgas cylinders within the enclosure to determine the resultant currentcount. In either manner of determining the number of items in theenclosure, correction algorithms can be applied to the data, as isillustrated in FIG. 11 below. In step 78, error correction may beaccomplished by error detection and including any standard meansavailable.

As discussed above, an historical correlation factor f may be receivedby a computing server at step 80. A database may store historicalcorrelation factors f locally or remotely, or they may be accessed, forexample, via the Internet. An historical correlation factor f may beapplied to the value or values obtained at step 78. Also, there may besituations in which the historical correlation factor f will not beapplied, or may be equal to 1, for example at step 82. As shown in FIG.10 item 84, data interpolation is used to make a prediction forcalculating when the number of units within the enclosure will bereduced to a predetermined number of units. Accordingly, at this pointit may not be necessary to utilize a character correlation factor f_(c)in step 86, and base the prediction upon only either the raw data ofstep 76, or the data after an historical correlation factor f has beenapplied and/or after a character correlation factor f_(c) has beenapplied. Alternatively, one or more characteristic correlation factorsfc may be applied at step 88.

With a prediction as to the when the number of units within theenclosure will be reduced to a predetermined number of units at step 90,at least two benefits may occur. First, a distributor will be lesslikely to make trips to fill the enclosure until the number of units inthe enclosure reaches an optimized number. Second, the distributor maybe less likely to run out of units in the enclosure because theprediction will allow the distributor to better estimate when theenclosure will run out of units, and therefore, the distributor can plana trip to fill the enclosure before its inventory runs out.

Turning to FIGS. 11 and 12 , depicted is the usage in raw data andcorrected data over three twenty-four hour periods. The number of unitspresent in the enclosure is known to be 30 units at zero hours (which isthe equivalent of 24 hours further down the scale). As is shown, overthe first twenty-four hour period, the dots indicated the raw data,wherein there is an anomaly in one data point that is corrected usingstandard correction methods. As mentioned previously with respect toFIG. 10 , the data can be sampled over any time intervals. The selectionof six hour time periods is for illustrative purposes. One or morecurves can be fitted to the data, which in this example, includes threeconsecutive days.

Referring to FIG. 12 , the ending balances of the three twenty-four hourperiod intervals shown in FIG. 11 is mapped. In one exemplary scenario,a distributor may determine that it is optimal to make a delivery to anenclosure when the 85% of the inventory originally available in theenclosure has been removed, which means that 15% of the inventory isstill available. A curve is fitted to those data points and provides atrajectory from the original fill day of Monday, and is depicted by adotted line. From the raw and/or corrected data, it appears thatoptimization would occur on the Tuesday, a week later. However, whencorrecting the trajectory by the application of either or both of thehistorical correlation factor f and the characteristic correlationfactor fc, the curve is adjusted whereby the resultant curve intersectsthe optimal 15% target for deliveries.

The historical correlation factor f as mentioned above can take intoaccount the behavior of inventory in previous weeks, for example, withrespect to the geographical area, and even as granular as the specificenclosures. The characterization correlation factor f_(C) might takeinto consideration, for example, weather conditions, seasons,approaching holidays, and special offers that bring in customers to theestablishment.

The disclosed method is for automatically auditing the number of unitswithin an enclosure having at least one door and at least one sensor forreliably tracking the inventory within an enclosure. Disclosed above isa device and method for determining when a door has been opened to apredetermined open position. Other methods involving at least one sensorfor reliably tracking the inventory within an enclosure were discussedabove. The data transmissions received via remote telemetry devicetransmissions can be corrected and subjected to manipulation including,but not limited to the application of a historical correlation factor fand a characterization correlation factor fc. In this manner, audit mayprovide predictions as to inventory depletion so that distributors canbetter plan for distribution, with the goal of better optimizingresources. This disclosure is intended to explain how to fashion and usevarious embodiments in accordance with the technology rather than tolimit the true, intended, and fair scope and spirit thereof. Theforegoing description is not intended to be exhaustive or to be limitedto the precise forms disclosed. Modifications or variations are possiblein light of the above teachings. The embodiment(s) was chosen anddescribed to provide the best illustration of the principle of thedescribed technology and its practical application, and to enable one ofordinary skill in the art to utilize the technology in variousembodiments and with various modifications as are suited to theparticular use contemplated. All such modifications and variations arewithin the scope of the appended claims, as may be amended during thependency of this application for patent, and all equivalents thereof,when interpreted in accordance with the breadth to which they arefairly, legally and equitably entitled.

What is claimed is:
 1. A method to automatically audit the number ofunits within an enclosure having at least one door, comprising:receiving from a remote telemetry device data indicating the number oftimes within a predetermined period of time a door has been opened to apredetermined open position relative to the enclosure, the predeterminedopen position of the door being specifically calibrated by a sensordevice being mechanically set when the sensor device is installed on theenclosure proximal to the door as a position of the door between aclosed position and a more fully opened position beyond thepredetermined open position, to generate a door opening count, whereinthe remote telemetry device includes a sensor configured to beadjustably calibrated to sense when the door is at the predeterminedopen position relative to the enclosure based upon the adjustablecalibration, to generate the door opening count.
 2. The method asclaimed in claim 1, further comprising: receiving a number of the unitspositioned within the enclosure at a prior particular time; anddetermining a current count of the units based on the data indicatingthe number of times within a predetermined period of time a door hasbeen opened to a predetermined open position relative to the enclosureand the number of units positioned within the enclosure at a priorparticular time.
 3. The method as claimed in claim 2, furthercomprising: applying an historical correlation factor to the currentcount to generate a prediction of when the units in the enclosure willreach a predetermined inventory.
 4. The method as claimed in claim 2,further comprising: applying a characteristic correlation factor to thecurrent count to generate a prediction of when the units in theenclosure will reach a predetermined inventory number.
 5. The method asclaimed in claim 1, wherein the remote telemetry device comprises an armsuch that when the door opens, the arm slides against the door resultingin a switch event when the door is opened to the predetermined openposition relative to the enclosure, the switch event resulting in sensoroutput.
 6. A remote telemetry device for automatically auditing thenumber of items within an enclosure having at least one door for removaland restocking of the items, comprising: a remote telemetry device incommunication with at least one sensor device configured to becalibrated, the calibration of the sensor device being set when thesensor device is installed based upon the size of an item, the sensorconfigured to detect the door opening to a calibrated door openposition, data indicative of the number of items within the enclosure todetermine a current count.
 7. The device as claimed in claim 6, whereinthe device is mechanically set during installation.
 8. The device asclaimed in claim 6, further comprising applying a historical correlationfactor to correct the current count to generate a prediction of when theitems in the enclosure will reach a predetermined inventory.
 9. Thedevice as claimed in claim 6, further comprising: applying acharacteristic correlation factor to the current count to generate aprediction of when the items in the enclosure will reach a predeterminedinventory number.
 10. The device as claimed in claim 6 wherein the itemis a gas cylinder.
 11. The remote telemetry device as claimed in claim6, further comprising an arm such that when the door opens, the armslides against the door resulting in a switch event when the door isopened to predetermined open position relative to the enclosure, theswitch event resulting in sensor output.